BORG Automotive Case Study

BORG Automotive Case Study

Until recently, 3D printing technology has been perceived as nothing more than a technological novelty. Nowadays, not only is it receiving exposure at some of the largest trade fairs in the world, but it has since become an integral part of the manufacturing process across countless industries. BORG Automotive has recently become one of the leading companies to implement additive manufacturing as a key component of the production process.

Based in Europe, BORG Automotive is a thriving enterprise in the automotive industry. With headquarters based in Silkeborg, Denmark, and a distribution centre in Zduńska Wola, Poland, BORG Automotive have established themselves as specialists in sales, production, and distribution in the auto aftermarket. Although the company’s domain lies primarily in the remanufacturing of alternators, starters, A/C compressors, and brake calipers to some of the world’s leading car manufacturers, the company also pays attention to agricultural and construction machinery.

An unwavering commitment to the quality of work they produce has made BORG one of Europe’s largest independent remanufacturing companies. As a result of their unwavering commitment, BORG have achieved things such as the regeneration of alternators with the starter function that is used in start/stop signs.

Quality and Innovation

Production in BORG Automotive is based on the principles of lean manufacturing, whereby all processes are optimized to ensure that production will be of the highest quality, whilst also being achieved quick and efficiently. Every stage of the technological process is strictly monitored to ensure that the consumers will be able to appreciate a product of superior quality.

“It is a natural part of our work to test manufactured products. We also put a lot of focus into the issue of R&D. In our research lab we are capable of testing our products under heavy loads in extreme temperatures and weather conditions. We are able to create new products as well as enhance the ones that are already on the market. The use of 3D Printers has definitely made the work more efficient.” – Grzegorz Stepien, R&D Technologist in BORG Automotive.

Flexibility and Cost Reduction

BORG Automotive uses 3D printers to produce components which are made of synthetic materials no longer available to purchase.The main feature of elements that are created in high temperature print technology is an elevated thermal and mechanical endurance.Contracting out the production of such components requires complex logistic procedures and can prove to be too costly and time-consuming.

“VSHAPER printers enable us to retain flexibility and independence. We can reduce the cost of production, which gives us an advantage over competition.” – Grzegorz Stepien, R&D Technologist in BORG Automotive.

The users of the printers at BORG Automotive make a strong point that the quality and precision of the product, as well as the close proximity of the service station, were decisive factors in choosing the printer. The ability to work continuously was also taken into consideration when deciding to purchase the device. This is especially important when the printer is being used for an industrial purpose.

Automotive and 3D Printing Technology Development

“More and more companies in the automotive industry are interested in printing construction elements that have virtues similar to that of metal. Observing the development of 3D Printing in recent years, it becomes apparent that automotive is its biggest recipient.” – Tomasz Szymanski, Founder and CEO of Verashape.

3D printing technology, until recently, has been used mainly in the process of rapid prototyping of models that serve as a base for testing parts. Implementing additive manufacturing in a small-lot production in BORG Automotive serves as a perfect example of how its use can be changed during the production processes. The phenomenon of using 3D printing to produce fully functional parts in the automotive industry has finally become a reality.